Note: Descriptions are shown in the official language in which they were submitted.
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Flexible multilayer flat material with reinforced cover layer
Description
The present invention concerns a flexible multilayer flat material which
contains at least one
wear layer and/or cover layer having at least one flat reinforcement material
located in it. In
particular, the invention concerns a flexible multilayer flat material
comprising at least one cover
layer, with at least one flat reinforcement material, preferably a nonwoven
material, embedded
in the cover layer. On one hand, the reinforcement material provides the
multilayer flat material
with improved mechanical properties, such as tensile strength andlor
resilience, and, on the
other hand, the reinforcement material simultaneously allows the decoration of
such flat
materials in its function as a printable image carrier.
Flat materials based on natural and/or artificial materials which have a
predetermined color
pattern are well known and are extensively used as wall, ceiling, and floor
coverings, and as
decorative films or artificial veneers. 1n particular, these types of
patterned flat materials based
on natural andlor artificial materials are used as flexible floor coverings.
Such flat materials
based on natural andlor artificial materials are typically produced by
premixing all components,
e.g. polymeric binders, colorants, fillers, additives, processing aids, and
other auxiliary
materials, and plastifying and granulating them via aggregates, e.g. internal
mixers, twin screw
extruders, and planetary roller extruders. The granulated particles are
subsequently pressed
into a web or a plate in compression aggregates, e.g. calenders, double belt
presses, or
stationary presses. The granulates used are typically multicolored. In this
type of floor covering
(homogenous floor coverings), patterning is thus only achieved via the
stochastic distribution of
the multicolored granulates by means of
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distortion, for example on calendars, or by means of compression. Such
coverings are
consequently not printed.
CV floor coverings (cushion vinyls) are currently widely used due to, among
other things, their
multiple decorative possibilities. To produce such CV floor coverings, PVC
plastisols are
typically applied to a carrier layer in a coating process and subsequently
gelled. The plastisols
hereby consist of PVC particles, plasticizers, stabilizers, and typical
auxiliary materials and
fillers, which sinter together to a matrix in the gelling oven. The plastisol
layer can hereby, as
the image carrier, be provided with multicolor gravure printing for
appropriate decorative design
and/or patterning of the covering. fn addition to further advantageous
properties, the possibility
of partial inhibition for production of surface texturing in the course of the
chemical foaming has,
in particular, ensured the wide dissemination of such materials. The partial
inhibition of the
expansion of the chemical foaming agent and thereby the production of a relief-
like structure of
the cover layer and/or the cover coating is hereby produced through the
addition of an inhibitor
to the printing inks used for the colored patterning. Various relief depths
are attained through
variation of the amount of inhibitor used. The patterning of surfaces through
the partial inhibition
of such a foaming process is, however, only applicable in those cases in which
the design of the
corresponding flat material provides a foam layer.
The patterning andlor texturing of the surfaces of floor coverings can also be
performed
according to the prior art by embossing the surfaces with the aid of embossing
rolls. This type
of process can, however, only be used if the coating compound which forms the
covering and/or
wear layer of the corresponding flat material is not duroplastic.
The CV floor coverings, however, generally requite a relatively large amount
of covering layer
material in order to ensure protection of the colored design,
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as otherwise the thin color layer wears off relatively quickly, Furthermore,
the imprinting
properties of such CV coverings are not always sufficient.
It is therefore the task of the current invention to provide a flexible
multilayer flat material that is
to have excellent material properties, such as mechanical tensile strength
and/or resilience, on
one hand, and is to simultaneously allow a variable decorative design while
retaining a
permanent pattern with predetermined color and shape and significantly
reducing costs on the
other hand. In particular, the patterning possibilities in the production of
such a flat material
should be such that technologically costly mixing, metering, and supplementary
processes
which occur in typical production methods can be dispensed with.
This task is solved by the embodiments characterized in the claims. In
particular, a flexible
rnultilayer flat material is provided which comprises at least one cover layer
having at least one
flat reinforcement material positioned in it. The expression that the cover
layer has at least one
flat reinforcement material positioned in it should be understood to mean,
among other things,
that a layer of the reinforcement material is embedded essentially over the
entire area of the
cover layer, andlor that the reinforcement material is completely surrounded
by the coating
compound andlor polymeric binders constituting the cover layer, so that a
closed layer is formed
around the reinforcement material. The reinforcement material can hereby be
positioned at any
level of the cover layer, provided that it is completely surrounded and/or
impregnated by the
coating compound constituting the cover layer.
The reinforcement material is preferably selected from the group of nonwoven
materials. The
nonwoven material can be a wet nonwoven material, a dry nonwoven material, or
a spunbonded
nonwoven material. In a preferred embodiment of the present invention, the
nonwoven material
used as the reinforcement material is a cellulose nonwoven material.
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The nonwoven material located as reinforcement material in the cover layer of
the flat material
according to the invention preferably has a weight in the range from 9 to 50
glm2.
In one embodiment of the present invention, the nonwoven material is printed
and/or provided
with printing. This printing can, for example, be a possibly colored pattern
or image. The
nonwoven material embedded andlor located in the cover layer according to the
invention
thereby acts not only as a reinforcement material, but can also be an image
carrier. In addition,
this type of image carrier can advantageously be printed in the primary color
space. Flexible
letterpress or inkjet printing is particularly suitable for the printing of
the nonwoven material
and/or nonwoven layer used as reinforcement material in the flat material
according to the
invention, and is, in addition, very favorably priced. A livelier image can
hereby be produced in
comparison to printing in the special color space, wherein the colors must
first be premixed. If
several printed layers of the preceding nonwoven material are used, decorative
3-D effects can,
for example, also be attained through appropriate harmonization.
The thickness of the cover layer of the multilayer flat material according to
the invention is
pr eferabiy at feast 00 Nm.
Any material which is suitable for the production of webs or plates,
particularly for elastic floor
coverings, can be used as the polymeric binder andlor coating compound for the
cover layer of
the flat material according to the invention. Coating compounds selected from
the group of
plastisols, dispersions, organosols, and lacquers will preferably be used for
the cover layer.
For example, plastics based on polyvinyl chloride (PVC), ethylene vinyl
acetate copolymer
(EVA), homopolyiTiers or copolymers of ethylenic unsaturated compounds, or a
mixture of
these, such as polyethylene, polypropylene, possibly with one or more
comonomers, ethylene
alkyl acrylate copolymers,
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and mixtures of these could be used for the cover layer. Furthermore,
terpofymers, such as
ethylene propylene diene mixed polymers (EPDM), block copolymers, such as
styrene isoprene
styrene (SIS), and styrene butadiene styrene (SBS) could be used. Of the
binders mentioned,
PVC is preferred.
Coating compounds based on renewable raw materials could also be used for the
cover layer.
In particular, a material containing a polyreaction product could be used as
the coating
compound for the cover layer, whereby the polyreaction products can be
obtained by reaction of
at least one dicarboxylic acid or polycarboxylic acid or their derivatives or
a mixture of these with
at least one epoxidation product of a carboxylic acid ester or a mixture of
these epoxidation
products and simultaneous or subsequent curing of the reaction product.
The reaction and/or curing of these reaction products is hereby essentially
performed with
(a) UV radiation in the presence of at least one UV initiator and/or
(b) electron beam radiation possibly in the presence of at (east one UV
initiator andlor
(c) IR radiation andlor
(d) thermal.
The UV initiators could be radical or cationic UV initiators or a mixture of
these UV initiator
types. Preferred examples of radical UV initiators are benzophenone,
benzophenone
derivatives, phosphine oxides, a-morpholinoketones, quinone, quinone
derivatives, or a-
hydroxyketones, or mixtures of these. Preferred examples of cationic UV
initiators are
triarylsulfonium salts, which could be of one type or be present as a mixture
of various
triarylsulfonium salts, or diaryliodonium salts, or a mixture of these. The UV
initiators are, for
example, present in a quantity of up to 8 weight percent, preferably 0.1 to 3
weight percent,
depending on the quantity of the material containing the reaction products.
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In addition to the UV initiator, at least one photosensitizer, such as, for
example, compounds
based on anthracene, perylene, or thioxanthene-9-one can be present which
activates the UV
initiator and can amplify its effect. The concentration of the UV initiator
can hereby be reduced.
The UV radiation used lies within the typical range, i.e. between 200 nm and
380 nm. The IR
radiation used lies within the typical range, e.g. 760 nm to 0.5 mm.
The dicarboxylic acids or polycarboxylic acids and/or their derivatives
preferably contain at least
one double bond per molecule.
Malefic acid, itaconic acid, fumaric acid, succinic acid, methyl succinic
acid, malic acid, or furan
dicarboxylic acid or a mixture containing at least two of these acids can
preferably be used as
the dicarboxylic acid. Acids with three or more carboxylic acid groups, for
example citric acid
and aconitic acid, can preferably be used as the polycarboxylic acid.
Anhydrides or partial esters or derivatives having at least one free
carboxylic acid group can be
used as derivatives of the dicarboxylic acids or polycarboxylic acids. The
alcohol components
of the partial ester are not subject to any particular r estrictions, however,
polyols such as
dipropylene glycol, propane diols, butane diols, hexane diols, hexane triols,
glycerin, or
pentaerythrite or a mixture containing at least two of these polyols are
preferably used as the
alcohol components.
In a particularly preferred embodiment, a mixture of a partial ester of
malefic acid anhydride and
dipropylene glycol is used as a cross-linker together with citric acid,
whereby the proportion of
citric acid is up to 50 weight percent, more preferably up to 25 weight
percent, depending on the
total amount of cross-linker.
The epoxidation product preferably contains more than one epoxy group per
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molecule. Epoxidized linseed oil, epoxidized soybean oil, epoxidized caster
oil, epoxidized
rapeseed oil or vernonia oil or a mixture containing at least two of these
epoxidized products
can preferably be used as the epoxidation product of a carboxylic acid ester.
The previously
defined alcohols of the partial esters, such as dipropylene glycol, propane
diols, butane diols,
hexane diols, hexane triols, or pentaerythrite or a mixture containing at
least two of these
polyols could also preferably be used as the alcohol components of this
carboxylic acid ester.
The carboxylic acid components are not subject to any particular restrictions.
Furthermore, the coating compound could contain at least one further additive,
consisting of, for
example, fillers, pigments for patterning, expanding agents andlor foaming
agents,
hydrophobification agents, and auxiliary materials.
The fillers for the previously mentioned coating compounds are preferably wood
flour, chalk,
cork flour, barium sulfate ("heavy spar"), slate flour, silicic acid, kaolin,
quartz flour, talcum,
lignin, cellulose, glass, textile, glass, or plant fibers, cellulose fibers,
polyester fibers, or for
example, colored granulate andlor chips from the preceding material containing
polyreaction
products, or a mixture containing at least two of these materials. Wood flour,
chalk, cellulose,
lignin, or cork flour, or a mixture containing at least two these fillers is
particularly preferred as a
filler. The proportion of filler relative to the total amount of the
corresponding coating compound
is preferably 15 to 80 weight percent.
Tall oil, synthetic or natural resins, such as balsamic resin, copal resin,
hydrocarbon resins,
and/or siccatives, such as compounds of the metals AI, Li, Ca, Fe, Mg, Mn, Pb,
Zn, Zr, Ce, or
Co, or a combination containing at least two these compounds could be used as
auxiliary
materials for the coating compounds, particularly the material containing
polyreaction products.
If necessary, antioxidants, UV stabilizers, and further typical auxiliary
materials, e.g. lubricants,
antistatics, or processing aids, could be added to the components from which
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the corresponding coating compounds are produced. These auxiliary materials
are well known
in and of themselves in this technical field.
In a preferred embodiment, the cover layer of the flat material according to
the invention is
transparent. In this case, the corresponding coating compound for the cover
layer contains no
more than two weight percent of filler. Similarly to the "oil spot
phenomenon," a transparent
development of the cover layer leads to the image printed on the embedded
nonwoven material
being clearly visible, while the fiber structure of the nonwoven is barely
optically perceptible.
The flat material according to the invention can be used in many applications,
preferably as a
wall, ceiling, or floor covering, a decorative film, or an artificial veneer.
Utilization as a floor
covering is particularly preferable.
The flat material according to the invention can be applied to a carrier
material. Any material
based on natural andlor synthetic films, fabrics, scrims, nonwovens, or knit
fabrics, as well as
textile materials, can be used as the carrier. In particular, carrier
materials used for carrier-
reinforced floor coverings could be used. Examples of these are jute fabric,
mixed fabrics made
of natural fibers, such as cotton and spun rayon, glass fiber fabrics, glass
fiber fabrics coated
with bonding agents, mixed fabrics made of synthetic fibers, and fabrics made
of cladded core
fibers with, for example, a core of polyester and a cladding of polyamide. A
coating of the glass
fibers made of a styrene butadiene latex can, for example, be used as the
bonding agent for
glass fiber fabrics. In principle, however, all materials suited for this
purpose could be
considered as carriers for the flat material, e.g. particle board, HDF, MDF,
and t_DF [high,
middle, and low density fiberboard] plates (i.e. particle or fiber board with
high, medium, or low
compression), inorganic plates (e.g. gypsum plasterboard), etc..
In a preferred embodiment, one or more flat
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nonwoven materials can be located under the cover layer. These nonwoven
materials located
under the cover layer could be the same as or different from the nonwoven
material located
and/or embedded in the cover layer as reinforcement material. The nonwoven
material layer
located under andlor laminated onto the cover layer is preferably a glass
fiber nonwoven
material. This arrangement of reinforced cover layer with a nonwoven material
layer laminated
onto it has particularly advantageous mechanical properties.
In another preferred embodiment of the present invention, a flexible
multilayer flat material is
provided, made of at least one carrier layer (() and at least one previously
defined cover layer
(II), possibly one backing coating (III) located under the carrier layer (I)
made of a chemically or
mechanically foamed foam layer, and possibly a compact or base coating (IV),
which is
positioned between the carrier layer (I) and cover layer (II) and/or between
the carrier layer (I)
and back coating (III}, whereby the coating compounds for the layers (111) and
(IV) are based on
one of the previously described materials.
The coating compounds for the flat material according to the invention can all
contain larger
amounts of filler, whereby in the compact coating preferably 10 to 60 weight
percent, particularly
30 weight percent, of filler is used, and in the chemical foam, 20 to 65
weight percent, preferably
35 weight percent, of filler is used, while the compounds for the mechanical
foam usually only
contain a small amount, preferably not more than 10 weight percent, e.g. 1 to
10 weight percent,
more preferably not more than 5 weight percent, of filler. All percent amounts
are always
relative to the total amount of the coating compounds, for example the
preceding material
containing reaction products, if not otherwise noted.
The coverings contain relatively large proportions of additives, particularly
mineral fillers from
the group including chalk, barium sulfate, silicic acid, kaolin, and talcum,
and if necessary,
however, also wood flour, cork flour, glass flour, cellulose, lignin, textile
fibers, or plant fibers,
which could also be present in the mixture, whereby the amount of filler in
the overall floor
covering can be up to 70 weight percent,
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in foam-free coverings preferably 30 to 60 weight percent, and in floor
coverings with chemically
foamed layers, preferably 40 to 60 weight percent of the overall floor
covering.
The flat materials according to the invention, i.e., for example, floor
coverings or tiles, will, if the
previously defined material containing polyreaction products is used for
assembly of the cover
layer (II) surrounding the reinforcement material as well as the further
layers (Ill) and (IV), be
produced in such a way that, for example, a combination of the previously
defined dicarboxylic
or polycarboxylic acids andlor their derivatives and epoxidation products in a
weight ratio of
1:0.3 to 1:8, particularly 1:0.5 to 1:3, 1:0.6 to 1:1.2 and 1:1 to 1:4,
fillers, and, in the compound
for the cover coating, possibly a hydrophobification agent, and, in the
coating for a chemical
foam, an expanding agent, and, if necessary, a foam stabilizer for each foam
compound, are
mixed and processed into a paste and this paste is then processed into
multilayer floor
coverings.
In compounds for chemically foamed layers, the amount of expanding agent lies
in the typical
range up to approximately 15 weight percent, whereby the amount of other
typical auxiliary
agents can range up to approximately 15 weight percent.
The floor covering preferably consists of three, four, or five layers, for
example a simple design
with the carrier, the reinforced cover layer, and a protective layer, or a
design with a compact
coating, possibly a chemical foam coating, and a transparent reinforced cover
layer, and a
carrier coating, and, if necessary, a chemically foamed backing coating,
whereby the chemical
foam could also, of course, be replaced by a mechanical foam or both types of
foam could be
present. In a particular embodiment of the invention, if a chemically foamed
layer (V) is
positioned between the compact coating and the reinforced transparent cover
layer, this foam
layer can be colored by the addition of appropriate colorants, such as
pigments, in such a way
that a colored decorative background for the image and/or pattern which is
printed on the
nonwoven material
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located in the cover layer is formed. Of course, the compact coating can also
be colored for this
purpose. The foamed layer (V) can also include the preferably UV-cured
material containing
polyreaction products previously defined. For this purpose, a paste is applied
to the compact
coating. This paste contains an expanding agent and a kicker; these include
polyols, urea, and
zinc, lead, or cadmium compounds, whereby ZnO, which lowers the decomposition
temperature
of the expanding agent, is preferred. The paste coating is then cross-linked
below the
decomposition teirtperature of the expanding agent, whereby if necessary an
inhibitor is added.
The inhibitor weakens the effect of the kicker or removes it completely, so
that the
decomposition of the expanding agent is displaced to higher temperatures.
Suitable substances
with inhibitory effect are, for example, benzotriazole derivatives,
trimellitic acid anhydride, and
similar substances. Various relief depths can be achieved through variations
of the amount of
inhibitor added. A protective layer (VI) made of polymers andlor copolymers or
waxes can be
located over this chemically foamed layer with applied relief pattern and the
cover layer lying
over it. Examples of these unsaturated curable lacquer systems are
polyacrylates,
polymethacrylates, polyurethanes, and mixtures of these. However, Carnauba
wax, for
example, can also be used. The protective layer is to be produced from
(co)polymers which are
compatible with the cover layer.
A further object of the present invention is a process for production of the
flat material previously
described, which comprises the application of the material constituting the
cover layer onto one
or more possibly printed flat reinforcement materials, particularly nonwoven
materials, in such a
way that the reinforcement material is thereby completely impregnated, and the
subsequent
hardening of this material for production of the cover layer, and the
application of this type of
cover layer to a carrier.
This particularly concerns a continuous process which, similarly to CV
production, features an
overall
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construction of a floor covering by sequential application of various pastes.
This type of process
can also, as already mentioned, include foaming, particularly chemical
foaming, in addition to
the insertion of the reinforcement material in the cover layer.
The production of the flat material according to the invention is performed,
for example, by
mixing the components to a paste, applying them in an appropriate thickness to
a web by
means of coating devices, foaming them if necessary, and, depending on the
selection of the
coating compound, hardening them in an appropriate way. Layers which contain
foaming agent
and layers which do not contain foaming agent can also be attached to the web
and foamed and
bonded in simultaneous or sequential steps.
In a further preferred embodiment, one or more further flat nonwoven materials
can be located
under the cover layer before the hardening of the cover layer. For this
purpose, the previously
described reinforced cover layer is combined in a typical lamination process
with one or mare
flat nonwoven materials, which can be the same as or different from the
nonwoven material
located andlor embedded in the cover Layer as reinforcement material, in such
a way that the
cover layer is bound to the further nonwoven material. For example, a printed
and/or' unprinted
cellulose nonwoven material is coated with transparent PVC plastisol on a
coating device and
laminated together with unprinted glass fiber nonwoven material. In a second
work cycle, a
backing coating is subsequently applied to the rear side of the glass fiber
nonwoven material,
pressed onto the front side of the transparent plastisol by means of screen
printing as a surface
texture, and subsequently gelled in the channel. Patterning of the surface can
also be produced
through embossing.
In a broad aspect, then, the present invention relates to flexible multilayer
sheetlike structure
comprising at least one top layer which includes disposed therein
substantially over the entire
surface at least one sheetlike reinforcing material, the reinforcing material
being completely
surrounded by the coating compositions which constitute the top layer so as to
form a
continuous layer around the reinforcing material, the reinforcing material
being a nonwoven
fabric having a weight in the range from 9 to 50 glmz.
In drawings which illustrate the present invention by way of example:
Fig. 1 shows a preferred embodiment of the flat material according to the
invention with a
carrier (I) having a base coating (IV) on both sides, a backing coating (III)
located below this, a
chemical foam coating (V) located on the upper base coating, and a cover layer
(II) located
above this, which then has
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a layer of nonwoven material embedded in it as reinforcement material.
Fig. 2 shows a preferred embodiment of the flat material according to the
invention with a cover
coating surface textured through screen printing having a possibly printed'
nonwoven material
embedded in it, a glass fiber nonwoven material laminated onto this, and a
backing coating
located under the glass fiber nonwvven material made of a chemically or
mechanically foamed
foam layer.
Fig. 3 shows a schematic depiction of a preferred embodiment for production of
the flat material
according to the invention, wherein a printed andlor unprinted cellulose
nonwoven material is
coated with transparent PVC plastisol and laminated together with an unprinted
glass fiber
nonwoven material in a first work cycle.
Fig. 4 shows the results in regard to tear strength of two different samples
as produced in the
following example.
Fig. 5 shows the results in regard to tear growth resistance of two different
samples as
produced in the following example.
The following example illustrates the invention.
Example:
Two cover layers based on the previously defined material containing
polyreaction products
with a thickness of 300 ~cm were applied to 0.4 mm thick paperboard. In one
sample, a 23 g
cellulose nonwoven material as additionally laminated on. Both samples were
subsequently
cured at 180°C and a dwell time of 6 minutes.
Formulation of the cover layer:
Epoxidized linseed oil 51.00 g
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Microdispersed succinic acid 2.00 g
PMMA 3.00 g
Linseed oil 2.00 g
Partial ester of dipropylene glycol and malefic acid 25.00 g
Siccative 1.10 g
The tear strength and tear growth resistance were subsequently measured on 2
cm thick strips
of both samples. The results are indicated in Figs. 4 and 5 in block diagrams.
The diagrams depicted in Figs. 4 and 5 indicate that in comparison to the
nonreinforced sample,
the sample in which the cellulose nonwoven material layer is located in the
cover layer provides
distinctly improved values in regard to tear strength and tear growth
resistance.
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